Page 2 - To locate your nearest; Thank you; From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2...
Page 5 - ELECTRIC SHOCK can kill.; SIGNIFICANT DC VOLTAGE exists in inverter power; FLYING METAL or DIRT can injure eyes.
OM-217 454 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2010 − 03 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will r...
Page 7 - EXHAUST SPARKS can cause fire.; STEAM AND HOT COOLANT can burn.; Using a generator indoors CAN KILL; ENGINE HEAT can cause fire.
OM-217 454 Page 3 1-3. Engine Hazards BATTERY EXPLOSION can injure. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Stop engine before disconnecting or connect- ing battery cables, battery charging cables (if applicable), or servicing battery. D Do no...
Page 8 - HOT PARTS AND FLUID can burn.; COMPRESSED AIR EQUIPMENT can
OM-217 454 Page 4 1-4. Hydraulic Hazards HYDRAULIC EQUIPMENT can injure or kill. D Incorrect installation or operation of this unit could result in equipment failure and personal injury. Only qualified persons should install, op- erate, and service this unit according to its Owner’s Manual, industry...
Page 9 - BREATHING COMPRESSED AIR can in-
OM-217 454 Page 5 HOT METAL from air arc cutting and gouging can cause fire or explosion. D Do not cut or gouge near flammables. D Watch for fire; keep extinguisher nearby. COMPRESSED AIR can injure or kill. D Before working on compressed air system, turn off and lockout/tagout unit, release pres- s...
Page 10 - WELDING WIRE can injure.; OVERUSE can cause OVERHEATING.; ARC WELDING can cause interference.
OM-217 454 Page 6 WELDING WIRE can injure. D Do not press gun trigger until instructed to do so. D Do not point gun toward any part of the body, other people, or any metal when threading welding wire. OVERUSE can cause OVERHEATING. D Allow cooling period; follow rated duty cycle. D Reduce current or...
Page 12 - UN CHOC ÉLECTRIQUE peut tuer.; Il reste une TENSION DC NON NÉGLIGEABLE dans les
OM-217 454 Page 8 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_rom_2010 − 03 Pour écarter les risques de blessure pour vous − même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification de...
Page 14 - Si des BOUTEILLES sont endomma-; -3. Dangers existant en relation avec le moteur
OM-217 454 Page 10 Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. D Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’ap...
Page 15 - Les ÉQUIPEMENTS HYDRAULIQUES
OM-217 454 Page 11 LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie. D Empêcher les étincelles d’échappement du moteur de provoquer un incendie. D Utiliser uniquement un pare-étincelles approuvé − voir codes en vigueur. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher ...
Page 17 - Les PIÈCES MOBILES peuvent causer
OM-217 454 Page 13 Une PRESSION D’AIR RÉSIDUELLE ET DES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures. D Détendre la pression pneumatique des outils et circuits avant d’entretenir, ajouter ou changer des accessoires et avant d’ouvrir le bouchon de vidange ou de remplissage d’huile du c...
Page 18 - LIRE LES INSTRUCTIONS.; -7. Proposition californienne 65 Avertissements
OM-217 454 Page 14 LES CHARGES ÉLECTROSTATI- QUES peuvent endommager les circuits imprimés. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imp...
Page 20 - SECTION 3
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 16 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Battery (Engine) Engine Temperature...
Page 22 - -3. Dimensions For Units With Optional Running Gear; Notes
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 18 4-3. Dimensions For Units With Optional Running Gear Dimensions B D A B C Height All Running Gear Options: 42-1/2 in. (1079 mm) (To Top Of Handle Assembly) A Protective Cage Width: 26 in. (660 mm) B Running Gear Width: 32...
Page 23 - SECTION 5; -1. Serial Number And Rating Label Location
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 19 SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated o...
Page 24 - -3. Grounding Generator To Truck Or Trailer Frame
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 20 ! Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. ! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Gen- erato...
Page 25 - Pros weld and cut
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 21 5-5. Connecting the Battery 804 197-A / Ref 216 171 / Ref. S-0756-D 1/2 in. Tools Needed: + − ! Connect negative ( − ) cable last. Notes Work like a Pro! Pros weld and cut safely. Read the safety rules atthe beginningof t...
Page 27 - Engine Left Side
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 23 12 11 15 16 17 18 Engine Left Side Engine Right Side ! Engine shown with doors remo- ved. Doors must be in place when engine is running. Engine must be cold and on a level sur- face. See maintenance label (Section 8-3) fo...
Page 28 - -8. Connecting To Weld Output Terminals
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 24 ! Do not connect to CC and CV terminals at the same time. 1 Work Weld Output Terminal 2 Stick/TIG (CC) Weld Output Terminal 3 Wire /CV Weld Output Terminal For MIG welding, connect work cable to Work terminal and wire fee...
Page 30 - Glow Plug Time
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 26 SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Engine Control Switches Ref. 240 604 1 Engine Control Switch Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs at idle speed at n...
Page 33 - Process/Contactor Switch Settings; Stick Start Procedure
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 29 Process/Contactor Switch Settings Switch Setting Process Output On/Off Control Electrode Hot − Wire MIG (GMAW) Electrode Hot Electrode Hot − Stick Stick (SMAW) Select Preferred Dig Electrode Hot Electrode Hot − Stick Air ...
Page 34 - TIG With Auto-Crater; Arc Start With Lift-Arc; OR
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 30 6-5. Lift-Arc t TIG With Auto-Crater t And Auto-Stop t WM Marketing Arc Start With Lift-Arc Arc End With Auto-Crater Arc End With Auto-Stop 1 2 1 2 2 1 3 3 4 Arc Start With Lift-Arc TIG Lift-Arc is used for the DCEN GTAW ...
Page 36 - SECTION 7
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 32 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles Ref 804 195-A / Ref 216 171-B ! If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. . Generator power decreases as weld...
Page 38 - SECTION 8
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 34 SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance ! Stop engine before maintaining. . See Engine Manual and Maintenance Labelfor important start-up, service, and storage information. Service engine more...
Page 40 - -3. Maintenance Label And Engine Maintenance Activities
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 36 8-3. Maintenance Label And Engine Maintenance Activities 4 3 3 1 8 2 7 6 5 7 ! Stop engine and let cool. Oil And Fuel 1 Oil Drain Valve 2 Oil Filter Change engine oil and filter according to en- gine manual. . Close valve...
Page 42 - A. Checking Fuel Solenoid
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 38 8-4. Adjusting Engine Speed . If the engine does not start and stop properly, verify the fuel solenoid is installed properly before adjusting engine speed (see Section A following). If the engine does not stay at idle spe...
Page 43 - B. Checking Throttle Solenoid
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 39 B. Checking Throttle Solenoid Ref. 804 197-A / 802 649 ! Stop engine. If the engine does not stay at idle speed, verify the the throttle sole- noid and linkage is installed proper- ly. Adjusting Throttle Solenoid 1 Thrott...
Page 44 - C. Making Engine Speed Adjustments
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 40 C. Making Engine Speed Adjustments Ref. 804 197-A / 801 963 . Before adjusting engine speed, verifythrottle solenoid is installed properly (see Section B on previous page). Check engine speeds (see table) with a tachomete...
Page 49 - SECTION 9; Recommended Spare Parts
. A complete Parts List is available at www.MillerWelds.com OM-217 454 Page 45 SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Recommended Spare Parts Quantity 187441 Element, Air Cleaner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 50 - ELECTRICAL DIAGRAMS; Figure 10-1. Circuit Diagram For Welding Generator
OM-217 454 Page 46 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator
Page 52 - RUN-IN AND WETSTACKING
OM-217 454 Page 48 SECTION 11 − RUN-IN AND WETSTACKING run_in_D722 9/05 11-1. Run-In And Wetstacking 1 Welding Generator Run-in procedures for this engine should not be required. Put unit into regular service.2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs i...
Page 53 - PERFORMANCE DATA
OM-217 454 Page 49 SECTION 12 − PERFORMANCE DATA 12-1. Fuel Consumption Curves 207 922-A / 207 923-A Idle Weld 3600 RPM 0 50 100 150 200 250 300 DC Weld Ampers At 100% Duty Cycle 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 US Gal./Hr . Idle 0 1 2 5 6 8 10 Auxiliary Power Kilowatts At 100% Duty Cycl...
Page 55 - Volts
OM-217 454 Page 51 226 756-A / 223 761-A The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown. A. CC/DC Stick Mode 12-4. Stick Mode Volt-Ampere Curves C . CC/AC STICK Mode Volts A...
Page 58 - GENERATOR POWER GUIDELINES; 3-2. Grounding Generator To Truck Or Trailer Frame
OM-217 454 Page 54 SECTION 13 − GENERATOR POWER GUIDELINES . The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 13-1. Selecting Equipment gen_pwr 2010 − 04 − ST-800 577 1 Generator Power Receptacles − Neutral Bo...
Page 59 - 3-3. Grounding When Supplying Building Systems
OM-217 454 Page 55 13-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #8 AWG or larger insulated copper wire.3 Ground Device . Use ground device as stated inelectrical codes. ! Ground generator to system earth ground if supplying power t...
Page 60 - 3-5. Approximate Power Requirements For Industrial Motors
OM-217 454 Page 56 13-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 140...
Page 61 - 3-7. Approximate Power Requirements For Contractor Equipment
OM-217 454 Page 57 13-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw ...
Page 63 - 3-10. Typical Connections To Supply Standby Power
OM-217 454 Page 59 13-10. Typical Connections To Supply Standby Power Transfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 1 2 3 4 5 Welding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safe...
Page 67 - (Equipment with a serial number preface of MA or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2010 − 01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding ...
Page 68 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Miller Electric Mfg. Co. 2010 − 01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 Internati...
